Cathode composite

ABSTRACT

This invention relates to a cathode composite for use in a primary battery and a secondary battery. In order to disperse uniformly a positive active material and a conductive agent in the cathode composite, the cathode composite is characterized by that it includes a compound having a pyridine ring in its molecular structure which will become a polar molecule, and functioning as a dispersant.

TECHNICAL FIELD

This invention relates to a cathode composite for use in a primary battery and a secondary battery.

BACKGROUND ART

As a lithium battery, for example, there are primary and secondary batteries, in which a chalcogen compound is used for a positive active material and metallic lithium is used for an anode. This type of battery has generally been composed of a cathode including a cathode composite, an anode including metallic lithium (forming the negative active material), and a separator. This type of battery has been formed by laying the cathode on the anode through the separator and by housing this laminate in a battery can or filling its peripheral edge with a sealing agent. Particles of positive active material, particles of carbon (such as carbon black) forming a conductive agent, polytetrafluoroethylene or solid polymer electrolyte (serving as a binder) and an organic solvent (serving as a diluent) are mixed and formed into a paste and either filled in or applied onto a substrate such as a stainless steel net or stainless steel plate, thus forming the cathode composite. The anode is formed by sticking a metallic lithium sheet onto the stainless steel plate or composed of the metallic lithium sheet alone.

However, the cathode composite has the following problems. When mixing the above materials to form a paste, the positive active material and the conductive agent cohere so as to worsen the wetting of them with the binder and organic solvent. For this reason, uniform mixing and uniform application on the substrate has been difficult, and additionally a surface of the prepared cathode composite is not uniform forming a corrugated shape. Therefore, the positive active material, the conductive agent and the binder are not dispersed uniformly in the above-mentioned cathode composite, so that the cathode composite sometimes cracks or peels off from the substrate. In addition, the initial capacity has been small as compared with the theoretical capacity in the primary battery using the above cathode composite, and the capacity is lowered to a value smaller than a half the initial capacity at 100 cycles in the secondary battery. Further, in the battery using the above cathode composite, convex surface portions have sometimes broken through the separator to reach the anode causing a short- circuiting.

This invention is made in order to solve the foregoing problems. An object of this invention is to provide a cathode composite, in which cracking, peeling-off from a substrate and short-circuiting can be prevented. Additionally with the invention a good discharge characteristic can be exercised when used in either a primary or secondary battery.

DISCLOSURE OF THE INVENTION

The cathode composite of this invention includes a compound with heteroatoms in its molecular structure which will become a polar molecule, and function as a dispersant.

Atoms of nitrogen, oxygen, phosphorus, sulfur and boron etc. may be mentioned as the heteroatom. When these heteroatoms are combined in an end portion, for example, of the molecular structure, a bias will be produced in the entire electron cloud in the above compound so that this compound will become the polar molecule.

The function as a dispersant means a function for preventing particles of solid from cohering or precipitating in liquid.

In this invention, the compound is adsorbed to surfaces of the positive active material and the conductive agent and sterically stabilized, so as to prevent the positive active material and the conductive agent from cohering and also improve wetting of the positive active material and the conductive agent to the organic solvent and the binder. For this reason, the positive active material, the conductive agent and the binder are dispersed uniformly so that these can be mixed uniformly and applied on the substrate evenly. In addition, a cathode composite having a uniform and non-corrugated surface can be obtained. Accordingly, the cracking, the peeling-off from the substrate and the short-circuiting can be prevented. Further, a good discharge characteristic can be exercised when the cathode composite is used for the primary battery, and a good charge/discharge characteristic can be exercised when it is used for the secondary battery.

When the above compound includes an acid structure, a discharge characteristic after a long-term preservation is made favorable by converting the part of the acid structure into a salt which is inactive to lithium thus forming a negative active material.

Structures based on phosphoric acid, sulfonic acid, boric acid, carboxylic acid and sulfuric acid etc., for example, may be mentioned as the above acid structure. When the above compound includes a reactive ethylene bond, the discharge characteristic after a long-term preservation is made favorable by bridging it with the binder.

Bonds of acrylic and methacrylic groups etc., for example, may be mentioned as the reactive ethylene bonds. As the positive active material for use in the cathode composite of this invention; MnO₂ may be mentioned for the primary battery and MoO₃, V₂ O₅, V₆ O₁₃, LiV₃ O₈, LiMn₂ O₄, LiCoO₂, LiCrO₂ and LiNiO₂ etc. may be mentioned for the secondary battery.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic vertical sectional view showing a structure of batteries of embodiments 1 through 15. FIG. 2 is a diagram showing initial discharge characteristics of embodiments 1 through 12 and a comparison example 1. FIG. 3 is a diagram showing discharge characteristics after preservation of 40 days at 60° C. of embodiments 1, 3, 9 and 10. FIG. 4 is a diagram showing energy densities per volume of the batteries of embodiments 1 through 12 and a comparison example 1. FIG. 5 is a diagram showing charge/discharge cycle characteristics of embodiments 13 through 15 and a comparison example 2.

BEST MODE FOR CARRYING OUT THE INVENTION

(Embodiment 1)

15 weight parts of MnO₂ serve as the positive active material for the primary battery, 1.5 weight parts of acetylene black serve as the conductive agent, 4 weight parts of electrolyte material serve as the binder, 0.45 weight part of compound shown by a formula (I) function as the dispersant, 8 weight parts of organic solvent formed by mixing cyclohexanone, methylethylketone and toluene serve as the diluent and 0.08 weight part of azobisisobutyronitrile serve as the reaction initiator, were mixed to prepare a paste of cathode composite. A mixture comprising monoacrylate of ethylene oxide, diacrylate of ethylene oxide and triacrylate of ethylene oxide were dissolved in propylene carbonate solution including lithium perchlorate with a concentration of 2 mol/l, so as to prepare the mentioned electrolyte material. Three kinds of acrylates forming the materials of the above mixture have molecular weights of about 200 respectively. ##STR1##

In the next step, the prepared paste was cast on a stainless steel substrate and left for 1 hour at 100° C. in an atmosphere of inert gas so as to be cured, so that a sheet-shaped cathode composite was prepared on the stainless steel substrate. A thickness of the prepared cathode composite was 51 microns on average, 56 microns maximum and 47 microns minimum.

In the third step, 0.05 weight part of azobisisobutyronitrile were dissolved in 10 weight parts of the above electrolyte material, and this solution was cast on the cathode composite and cured in the same way as above, so that an electrolyte film was formed on the cathode composite. A thickness of the prepared electrolyte film was 20 microns.

A composite sheet thus prepared comprising the stainless steel substrate, the cathode composite and the electrolyte film was cut out into a piece of 1 cm by 1 cm square. Metallic lithium having a thickness of 100 microns was attached to the electrolyte film of this composite sheet for serving the anode so as to make up a battery having a structure shown in FIG. 1, that is, comprising a stainless steel substrate 1, a cathode composite 2, an electrolyte film 3, an anode 4 and a stainless steel substrate 5.

A load of 1 kg/cm² was applied to the prepared battery, and an initial discharge test was done under this condition at 25° C. with a constant current of 0.1 mA/cm². As a result, a cathode utilization factor of 80% was obtained. A filling rate of active material per volume of cathode composite was 30 volume percents.

In place of the compound shown in formula (I), a compound may be used in which n is 9 through 16 in the formula (I) or X is a halogen atom. Further, a compound having a basic structure different from that of the formula (I) may be used, provided that the compound includes a nitrogen containing group in the molecular structure which will become the polar molecule, and function as the dispersant.

(Embodiment 2)

A battery was made up in the same way as embodiment 1 except that a compound shown by formula (II) functioning as the dispersant was used in place .of the compound shown in the formula (I). ##STR2##

A thickness of the cathode composite of the prepared battery was 53 microns on average, 57 microns maximum and 50 microns minimum.

The initial discharge test same with the embodiment 1 was done on the prepared battery, and a cathode utilization factor of 83% was obtained. A filling rate of active material per volume of cathode composite was 32 volume percents.

In place of the compound shown in the formula (II), a compound may be used in which n is 9 through 16 and m is 8 and 10 through 16 in the formula (II). Further, a compound having a basic structure different from that of the formula (II) may be used, provided that the compound includes an acyl group in the molecular structure which will become the polar molecule, and function as the dispersant.

(Embodiments 3 through 9)

Batteries were made up in the same way as the embodiment 1 except that compounds shown by formulas (III) through (IX) functioning as the dispersant were used respectively in place of the compound shown by the formula (I). Thicknesses of the cathode composites, results of discharge test and filling rates of active material per volume of cathode composites are listed in Table 1 for respective prepared batteries. ##STR3##

                                      TABLE 1                                      __________________________________________________________________________                               Discharge                                                                      utilization                                                                    factor                                                              Thickness  (%)                                                                 of cathode     After  Filling rate                                     Compound                                                                               composites     preservation                                                                          of active                                        used as (μm)        of 40 days                                                                            material                                  Embodiment                                                                            dispersant                                                                             Average                                                                             Max.                                                                              Min.                                                                              Initial                                                                            at 60° C.                                                                      (vol %)                                   __________________________________________________________________________     3      formula (III)                                                                          55   56 54 85  50     36                                        4      formula (IV)                                                                           56   58 53 83  --     34                                        5      formula (V)                                                                            55   58 52 83  --     30                                        6      formula (VI)                                                                           54   55 52 83  --     32                                        7      formula (VII)                                                                          56   59 52 81  --     30                                        8      formula (VIII)                                                                         57   59 55 82  --     35                                        9      formula (IX)                                                                           55   56 53 87  52     36                                        __________________________________________________________________________

In place of the compound shown in formula (III), a compound may be used in which n is another integer and m is 1 through 7 and 9 through 80 in the formula (III). Further, in place of the compound shown in formula (IV), a compound may be used in which n is another integer and m is 1 through 7 and 9 through 30 in the formula (IV). Moreover, in place of the compound shown in the formula (V),, a compound may be used in which n is another integer in the formula (V). Furthermore, in place of the compound shown in the formula (VI), a compound may be used in which n is another integer and m is 1 through 7 and 9 through 30 in the formula (VI). Still further, in place of the compound shown in the formula (VII), a compound may be used in which n is another integer in the formula (VII). Still further, in place of the compound shown in the formula (VIII), a compound may be used in which n is another integer and m is 1 through 7 and 9 through 30 in the formula (VIII). Still further, in place of the compound shown in the formula (IX), a compound may be used in which n is another integer and m is 1 through 7 and 9 through 80 in the formula (IX). Compounds having basic structures different from those of the formulas (III) through (IX) may be used, provided that the compounds include an acid in the molecular structure which will become the polar molecule and function as the dispersant. Structures based on phosphoric acid, sulfonic acid, boric acid, carboxylic acid and sulfuric acid etc., for example, may be mentioned as the acid structure.

(Embodiment 10)

A battery was made up in the same way as embodiment 1 except that a compound shown by formula (X) functioning as the dispersant was used in place of the compound shown by the formula (I). The compound shown in the formula (X) has a methacrylic group including a reactive ethylene bonding. ##STR4##

A thickness of the cathode composite of the prepared battery was 53 microns on average, 54 microns maximum and 52 microns minimum.

The initial discharge test (same as with embodiment 1) was done on the prepared battery, and a cathode utilization factor of 85% was obtained. In the discharge test after preservation of 40 days at 60° C., a cathode utilization factor of 60% was obtained. A filling rate of active material per volume of cathode composite was 36 volume percents.

In place of the compound shown in formula (X), a compound may be used in which m is 1 through 7 and 9 through 80 in the formula (X). A compound may be used which has an acrylic group in place of the methacrylic group. Further, a compound having a basic structure different from that of the formula (X) may be used, provided that the compound includes a reactive ethylene bonding in the molecular structure which will become the polar molecule and function as the dispersant.

(Embodiment 11)

A battery was made up in the same way as embodiment 1 except that 0.75 weight part of compound (molecular weight: 10,000) shown in a formula (XI) functioning as the dispersant were used in place of the compound shown by the formula (I). 10 weight parts of benzene were used as the diluent. The compound shown in formula (XI) was formed in such a way that polyethylene glycol was esterified by acrylic acid or methacrylic acid and phosphoric acid, and the obtained ester material was polymerized by reactive double bonding of the acrylic group or methacrylic group. ##STR5##

A thickness of the cathode composite of the prepared battery was 50 microns on average, 53 microns maximum and 47 microns minimum.

The initial discharge test (same as with embodiment 1) was done on the prepared battery, and a cathode utilization factor of 85% was obtained. A filling rate of active material per volume of cathode composite was 35 volume percents.

In place of the compound shown in the formula (XI), a compound may be used which has a structure identical with that of formula (XI) but differing in molecular weight.

(Embodiment 12)

A battery was made up in the same way as embodiment 1 except that 0.75 weight part of poly-2-vinylpyridine (molecular weight: 150,000) shown by formula (XII) functioning as the dispersant were used in place of the compound shown by formula (I). 10 weight parts of benzene were used as the diluent. ##STR6##

A thickness of the cathode composite of the prepared battery was 50 microns on average, 53 microns maximum and 47 microns minimum.

The initial discharge test (same as with embodiment 1) was done on the prepared battery, and a cathode utilization factor of 85% was obtained. A filling rate of active material per volume of cathode composite was 35 volume percent.

In place of the compound shown in formula (XII), a compound which has a structure the same as formula (XII) and a molecular weight different :from it within a range of 10,000 to 250,000, may be used.

(Comparison Example 1)

A battery was made up in the same way as the embodiment 1 except that a compound functioning as the dispersant was not used.

Cohering particles of MnO₂ and acetylene black were formed on the cathode composite of the prepared battery, and there was a part having a thickness reaching 500 microns. A thickness of the cathode composite other than the part on which the cohering particles were formed was 61 microns in average, 72 microns maximum and 51 microns minimum.

The initial discharge test (same as with embodiment 1) was done on the prepared battery, and a cathode utilization factor of 70% wets obtained. In the discharge test after preservation of 40 days at 60° C., a cathode utilization factor of 45% was obtained. A filling rate of active material per volume of cathode composite was 23 volume percents.

FIG. 2 is a diagram showing initial discharge characteristics of the embodiments 1 through 12 and comparison example 1. In FIG. 2, A₁₋₁₂ shows the initial discharge characteristics of the embodiments 1 through 12, and B₁ shows the initial discharge characteristic of the comparison example 1.

FIG. 3 is a diagram showing discharge characteristic after preservation of 40 days at 60° C. In FIG. 3, A₁ shows a discharge characteristic of the embodiment 1, A₃ shows that of the embodiment 3, A₉ shows that of embodiment 9 and A₁₀ shows that of embodiment 10, respectively.

As seen from both diagrams, the discharge characteristics of embodiments 1 through 12 were better than that of comparison example 1.

FIG. 4 shows energy densities per volume of batteries of embodiments 1 through 12 and comparison example 1. As is obvious from FIG. 4, even the energy densities per volume of batteries of embodiments 1 through 12 were better than that of comparison example 1.

As described above, since the cathode composite for use in the primary batteries shown in embodiments 1 through 12 include compounds functioning as the dispersant, the following effects are obtainable. In the cathode composite, the positive active material and conductive agent are dispersed uniformly and the surface of sheet-shaped cathode composite becomes smooth without corrugation. As a result, the cracking, the peeling-off from the substrate and the occurrence of short-circuiting can be prevented. Further, the utilization factor of positive active material is improved so that the battery capacity can be increased and good discharge characteristics can be exercised. Moreover, the filling density of active material per volume of cathode composite is improved such that the energy density per volume of battery can be improved.

(Embodiment 13)

15 weight parts of LiMn₂ O₄ serving as the positive active material for the secondary battery, 1.5 weight parts of acetylene black serving as the conductive agent, 4 weight parts of electrolyte material serving as the binder, 0.45 weight part of compound shown in formula (XIII) functioning as the dispersant, 8 weight parts of organic solvent formed by mixing cyclohexanone, methylethylketone and toluene serving as the diluent, and 0.08 weight part of azobis-isobutyronitrile serving as the reaction initiator, were mixed to prepare a paste of cathode composite. The compound shown in formula (XIII) has an acrylic group having the reactive ethylene bonding. A mixture comprising monoacrylate of ethylene oxide, diacrylate of ethylene oxide and triacrylate of ethylene oxide was dissolved in propylene carbonate solution including lithium hexafluoro-arsenate with a concentration of 2 mol/l, so as to prepare the mentioned electrolyte material. Three kinds of acrylates forming the materials of the above mixture have molecular weights of about 200 respectively. ##STR7##

In the next step, the prepared paste was cast on a stainless steel substrate and left for 1 hour at 100° C. in an atmosphere of inert gas so as to be cured, so that a sheet-shaped cathode composite was prepared on the stainless steel substrate. A thickness of the prepared cathode composite was 53 microns on average, 55 microns maximum and 51 microns minimum.

In the third step, 0.05 weight part of azobis-isobutyronitrile was dissolved in 10 weight parts of the above electrolyte material, and this solution was cast on the cathode composite and cured in the same way as above, so that an electrolyte film was formed on the cathode composite. The thickness of the prepared electrolyte film was 20 microns.

A composite sheet thus prepared comprising the stainless steel substrate, the cathode composite and the electrolyte film was cut out into a piece of 1 cm by 1 cm square. Metallic lithium having a thickness of 100 microns was attached to the electrolyte film of this composite sheet serving as the anode so as to make up a battery having a structure shown in FIG. 1, that is, comprising a stainless steel substrate 1, a cathode composite 2, an electrolyte film 3, an anode 4 and a stainless steel substrate 5.

A load of 1 kg/cm² was applied on the prepared battery, and the charge/discharge test was done under this condition at 25° C. with a constant current of 0.1 mA/cm². As a result, an initial capacity of more than, or equal to, 80% was maintained even after charging and discharging of 100 cycles. A filling rate of active material per volume of cathode composite was 35 volume percent.

In place of the compound shown in the formula (XIII), a compound may be used, in which m is 1 through 7 and 9 through 80 in the formula (XIII). Further, a compound may be used, which has a methacrylic group in place of the acrylic group. Moreover, a compound having a basic structure different from that of the formula (X][II) may be used, provided that the compound includes the reactive ethylene bonding in the molecular structure which will become the polar molecule, and functions as the dispersant.

(Embodiment 14)

A battery was made up in the same way as the embodiment 13 except that 0.75 weight part of compound (molecular weight: 10,000) shown by the formula (XI) functioning as the dispersant were used in place of the compound shown by the formula (XIII). 10 weight parts of benzene were used as the diluent.

A thickness of the cathode composite of the prepared battery was 50 microns on average, 54 microns maximum and 45 microns minimum.

The charge/discharge test (same as with embodiment 13) was done on the prepared battery, and a capacity of more than or equal to 80% of the initial capacity was maintained even after charging and discharging of 100 cycles. A filling rate of active material per volume of cathode composite was 35 volume percent.

In place of the compound shown in formula (XI), a compound may be used, which has a structure the same as formula (XI) and a molecular weight different from it.

(Embodiment 15)

A battery was made up in the same way as the embodiment 13 except that 0.75 weight part of poly-4-vinylpyridine (molecular weight: 140,000) shown by a formula (XIV) functioning as the dispersant were used in place of the compound shown by formula (XIII). 10 weight parts of benzene were used as the diluent. ##STR8##

A thickness of the cathode composite of the prepared battery was 50 microns on average, 54 microns maximum and 45 microns minimum.

The charge/discharge test (same as with embodiment 13) was done on the prepared battery, and a capacity of more than or equal to 80% of the initial capacity was maintained even after charging and discharging of 100 cycles. A filling rate of active material per volume of cathode composite was 35 volume percent.

In place of the compound shown in formula (XIV), a compound may be used, which has a structure the same as formula (XIV) and a molecular weight different from it within a range of 10,000 to 250,000.

(Comparison Example 2)

A battery was made up in the same way as embodiment 13 except that a compound functioning as the dispersant was not used.

Cohering particles of LiMn₂ O₄ and acetylene black were formed on the cathode composite of the prepared battery, and there was a part having a thickness reaching 500 microns. A thickness of the cathode composite other than the part on which the cohering particles were formed was 58 microns on average, 66 microns maximum and 49 microns minimum.

The charge/discharge test (same as with embodiment 13) was done on the prepared battery, and a capacity after charging and discharging of 100 cycles was smaller than or equal to 50% of the initial capacity.

FIG. 5 is a diagram showing charge/discharge cycle characteristics of the embodiments 13 through 15 and the comparison example 2. In FIG. 5, A₁₃₋₁₅ shows the charge/discharge cycle characteristics of the embodiments 13 through 15, and B₂ shows the charge/discharge cycle characteristic of the comparison example 2. As seen from FIG. 5, the charge/discharge cycle characteristics of the embodiments 13 through 15 are better than that of the comparison example 2.

As described above, since the cathode composite for use in the secondary batteries shown in embodiments 13 through 15 include compounds functioning as the dispersant, the following effects are obtainable. In the cathode composite, the positive active material and the conductive agent are dispersed uniformly and the surface of sheet-shaped cathode composite becomes smooth without corrugation. As a result, the cracking, the peeling-off from the substrate and the occurrence of short-circuiting can be prevented. Further, the utilization factor of positive active material is improved so that the battery capacity can be increased and the good charge/discharge characteristic can be exercised. Moreover, the filling density of active material per volume of cathode composite is improved so that the energy density per volume of battery can be improved.

INDUSTRIAL APPLICABILITY

This cathode composite can be effectively utilized to make a primary battery with an excellent discharge characteristic and a secondary battery with an excellent charge/discharge characteristic. 

What is claimed is:
 1. A cathode composite comprising (i) a polar organic macromolecule having a pyridine ring, (ii) a chalcogen-containing positive active compound, (iii) a conductive agent, and (iv) a diluent; wherein the polar organic macromolecule having a pyridine ring functions as a dispersant for the positive active compound and the conductive agent.
 2. A cathode composite as set forth in claim 1, wherein said polar organic macromolecule is poly-2-vinylpyridine or poly-4-vinylpyridine. 